APAL: AUTOPALLET(P3) + AUTOLOADER(T3)

FOR DAMAGE-FREE, HIGH PRODUCTIVITY,

CUSTOMER FRIENDLY SHIPMENTS

April 4th 2016

1
Agenda
1 APAL Overview

2 APAL Landscape
3 APAL Processes & Integration with EWM
4 APAL Master Data
5 Zanesville APAL Processes
6 APAL Tools
7 PISTLO Load Overview Screen
8 APAL FAQs
9 Questions?

2
1. APAL Overview

APAL: Autopallet(P3) + Autoloader(T3).

APAL-AutoPallet(P3) that generates case pick lists that, if
followed, minimize in-transit damage, increase quality of
sets (picked pallets), and enhance productivity.
APAL-AutoLoader(T3) that generates staging and/or
loading sequences that, if followed, minimize in-transit
damage, meet axle-weight restrictions and bridge laws, and
enhance productivity.
APAL is a parameter driven application.

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2. NESTL'S APAL LANDSCAPE

4
2 APAL Landscape

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2 APAL Landscape

Currently a single APAL server is being used for NUSA and

NPPC EWM warehouses.
There are 2 production servers called primary and
secondary and both are always kept with the same level of
updates.
Any new EWM warehouse going live with EWM will reside
on the same APAL server.

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3. APAL PROCESSES & INTEGRATION
WITH EWM

7
3 APAL Processes

SAP SOS
Shipment
data

Shipment data w/allocs

APAL Black box

SAP eWM
Case pick, staging and loading
instructions/Sequences
3 APAL Processes

Shipment

Build Pallets Case Picking / Pallet

AutoPalletP3 Building Instructions

Pallet
Profiles
Optimization Request Pallet
Recalculation

Build Truck Loads

AutoLoaderT3

Loading
Diagrams

Page 9
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3 APAL Processes
EWM calls APAL, sending it the following shipment info:
General shipment data warehouse, assigned trailer, carrier
Order data customer, stop, load point
Order materials material number, total ordered quantity
Order material allocation(s) - an allocation is included for each EWM bin assignment and the
quantity to be picked from that bin. Allocation(s) must total to the materials ordered quantity.
APAL loads the shipment data to its database
APAL builds case pick pallet sets
APAL looks for less than full unit allocations and builds case pick pallet sets considering all the
APAL picking parameter settings defined for the warehouse, or customer or order if exists
Once releasing waves, all allocations on a case pick pallet must belong to the same wave
release

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3 APAL Processes

APAL builds shipment load plan

APAL takes the case pick pallet sets and full unit allocations and calculates a load plan
considering all the APAL loading parameter settings defined for the warehouse, or specific
shipment if exists
APAL will run thru its load plan creation processing multiple times (# of times is a parameter
setting), and will keep the best load plan to send back to EWM.
If APAL cannot create a legal load plan with the case pick pallet sets it built, it will go back, build
them differently and try again
If APAL still fails to create a legal load plan, the best of the illegal load plans will be sent back
to EWM with a 0 score
APAL sends the following information back to EWM:
Pallet build data - case pick and full units along with pallet platform type
Pallet loading sequence data loading sequence, row, side, level, turn specification, type (full or
case), airbag (yes or no)
Message data any APAL errors or warning messages created with the load plan
Load plan overall data load plan score, case count, pallet count, floorspot count, drive, steer
and trailer axle weights and limits, and the rear tandem axle setting.

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4. APAL Master Data

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4 APAL Master Data

Warehouse mapping of pick locations, aisles, doors

Uses x,y coordinates for travel distance and accessibility between
locations
Material master
Data feed from SAPs SOS
Permits override values that are entered thru APAL web application
Product Grouping
SAPs SOS sends sales hierarchy product grouping in the material master
feed
Packaging grouping currently maintained manually directly in APAL thru
APAL web application

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4 APAL Master Data
Trailers
APAL trailer ids use the SAP Vehicle Type Ids
Includes dimension measurements and weights, and axle weights and
positioning
State Axle Restrictions
Uses warehouses state and destinations state restrictions in calculations
for axle weight limits and measurements end point with the most
restrictive limits is what is used for the load plan
Customer master
Master data maintained automatically with each shipment sent to APAL
Can setup APAL parameter settings specific to a customer/warehouse
relationship

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5. ZANESVILLE APAL PROCESSES

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5 ZANESVILLE APAL PROCESSES

Case Pick?
Shipment Load Optimization
Shipment Load pattern
Axle Weight Restrictions
Weight Distribution
Damage free shipment
Customer stop sequence

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5 ZANESVILLE APAL PROCESSES
What is more important?
I know you cant keep all the rules all the time.
Here is what I think the priorities are:
Constraints
1. Make the axles legal
2. Keep stops separate( if we have multiple stops)
3. Check weight Distribution
4. Check total volume of trailer
Objectives
1. Keep orders separate (if you can)
2. Turn last 2 pallets (if you can)
3. Meet desired customer loading pattern
4. Keep same items together
5. Keep families together

www.WarehouseOptimization.com Page 17
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6. APAL Tools

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6 APAL Tools

APAL is accessed by using web browser.

3D Load Diagram
2D Load Diagram

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6. APAL Tools

APAL 3D Load Diagram

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6. APAL Tools

APAL 2D Load Diagram

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7. PISTLO LOAD OVERVIEW
SCREEN

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7 PISTLO Load Overview Screen

The POSN column on the PISTLO load overview screen

includes the details on where and how to place the pallet unit
into the trailer

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7 PISTLO Load Overview Screen
Pos 1 -2 Starting from the nose of the
trailer, the row to place the unit (01,
02, 03, .)

Pos 3Column in the row to place the

unit (L-Left, C-Center, R-Right)
L C R

Pos 4 Level of the unit in the

floorspots stack, starting on the floor
C
B
A

Pos 5 Orientation of the unit

placement in the floorspot (T turn
and load wide side out,no value load
narrow side out) T

Pos 6Indicates if the units in the row

are to be staggered to the right or left
sides or not at all

See next slide for description of Pos 6

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7 PISTLO Load Overview Screen

Position 6:
Indicates if the units in the row are to be staggered to the right or left sides or not at
all. See the diagram below for the unit placements for the different column/stagger
combinations.
(R stagger to the right, L stagger to the left, 0 no stagger)
NOTE: For NO stagger Center floor spots stay in the center of the row, Left and
Right side floor spots go against their sides trailer wall
C/0

L/R R/R

L/L R/L

L/0 R/0

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7 PISTLO Load Overview Screen

Here is a representation of the pallet unit placements as they

are defined in the above PISTLO Load Overview screen
example.

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8. APAL FAQS

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8 Frequently Asked Questions
8.10 APAL Frequently Asked Questions
8.10a - What does the APAL score mean?

8.10b - Why does APAL sometimes create short case pallet builds?

8.10c - Case pick build: Why material allocation into 2 separate picks?

8.10d - APAL Pallet Positioning and Loading Sequence

8.10e - How to read the information listed in the APAL loading diagram

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8.10A: WHAT DOES THE APAL
SCORE MEAN?

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8.10A: What Does the APAL Score Mean?

Any score above 0 means the APAL load plan is legal and
can be used by the warehouse.
A legal load plan is one where all the pallets fits inside the
trailer walls, does not exceed the steer, drive and rear
tandem axle weight limits or breaks any of the constraints
set in APAL.
The score does not necessarily reflect the quality of the
load plan.
APAL has hundreds of constraint, parameter and objective
settings that are considered in the creation of a shipments
load plan.

Continued on next slide

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8.10A: What Does the APAL Score Mean?

For most shipments, APAL has to break some of the

parameter or objective settings as it tries to create a legal
load plan. If this happens, APAL takes points away from
the total scoring of the solution. On the other hand, APAL
constraints cannot be broken.
If a constraint is broken the load plans score will
immediately be set to 0 and the plan will not be legal for
shipping.

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8.10E. HOW TO READ THE
INFORMATION LISTED IN THE
APAL LOADING DIAGRAM

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8.10E How to read the information listed in the APAL loading diagram

Information listed in the APAL loading diagram

1 6
5

4
2

3
1. Row number
2. Left side of trailer
3. Insert Airbag
4. Level A (floor)
5. Level B
6. Right side of trailer

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8.10E How to read the information listed in the APAL loading diagram
Information for a Full Unit Pallet

material id The 8 digit Globe material id

pick bin Bin the full unit will be picked from / will see loaded instead if full unit wave is already released
and unit is locked down to the floorspot

unit weight Weight of the full unit plus the assigned packaging material (in lbs)

above supp wt Total weight the unit can support being stacked on top of it (in lbs)

unit height Height of the full unit plus the assigned packaging material (in inches)

unit length Layer length of the material, not the packaging material (in inches)

unit width Layer width of the material, not the packaging material (in inches)

material upc Will list as much of the materials upc that can fit into the box many times it is truncated

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8.10E How to read the information listed in the APAL loading diagram
Information for a Case Pick Pallet

case pick set id The 8 digit Globe material id

staged/loaded status staged if the wave for the case pick set was released
loaded if the case pick set was already picked and loaded to the trailer
No value if the case pick wave this unit belongs to has not been released yet.

unit weight Weight of the full unit plus the assigned packaging material (in lbs)

above supp wt Total weight the case pick set can support being stacked on top of it (in lbs)A 0 value usually
means the case pick set does not have a full top layer so it cant support another pallet being
placed on top of it.

unit height Height of the case pick set unit plus the assigned packaging material (in inches)

unit length Layer length of the case pick set, not the packaging material (in inches)

unit width Layer width of the case pick set, not the packaging material (in inches

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Wrap-up

A good shipment load plan depends on a

valid material master data
AND
the correct trailer assignment

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QUESTIONS?

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